SSR M90 M110 M132 M160 OPERATION AND MAINTENANCE MANUAL
This manual contains important safety information and must be made available to personnel who operate and maintain this machine.
M90
SERIAL No
2360446
M110
SERIAL No
2380444 –>
M132
SERIAL No
2400244
M160
SERIAL No
2420400 –>
C.C.N. DATE
: 54624838 GB : JU JUNE NE 20 2002 02
–>
–>
Machine models represented in this manual may be used in various locations world–wide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. direc tives. In such cases, the design specification of this machine has been certified as complying complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid. A declaration of that conformity follows:
EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES 98/37/EC, 93/68/EEC, 89/336/EEC WE, WE, INGERSOLL –RAND –RAND COMPANY LIMITED SWAN LANE HINDLEY GREEN WIGAN WN2 4EZ UNITED KINGDOM
DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY, THE PRODUCT(S)
M90 M110 M132 M160 TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS. EN29001, EN292, EN60204 –1, –1, EN1012, EN50081, EN50082 ISSUED AT HINDLEY GREEN ON 01/01/2002 BY H.SEDDON, QUALITY ASSURANCE MANAGER.
H. SEDDON
EC Pressure Equipment Directive and Related Regulations We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive. It may carry ”CE” marking in compliance with other applicable EC Directives. 06/02
CONTENTS & ABBREVIATIONS ABBREVIATIONS & SYMBOLS
CONTENTS 1
CONTENTS
2
FOREWORD
3
ISO SYMBOLS
8
SAFETY
10
GENERAL INFORMATION
17
INSTALLATION / HANDLING
22
OPERATING IN INSTRUCTIONS
25
AIRCARE WARRANTY
26
MAINTENANCE
33
FAULT FINDING
1
## # #
Contact Ingersol – l– Rand Rand for serial number
–>#### –>#### Up to Serial No. #### –> –> From Serial No. *
Not illustrated
†
Option
NR
Not required
AR
As required
SM
Sitemaster/Sitepack
HA
High ambient machine
WC
Watercooled machine
AC
Aircooled machine
ERS
Energy recovery system
T.E.F.C. Totally enclosed fan fa n cooled motor (IP54) O.D.P.
Open drip proof (motor)
ppm
parts per million
BR
Brazil
CN
China
DE
Germany
DK
Denmark
ES
Spain
FI
Finland
FR
France
GB
Great Britain (English)
IT
Italy
NL
Holland
NO
Norway
PT
Portugal
SE
Sweden
US
United States
M90 M110 M132 M160
2
FOREWORD
The contents of this manual are considered to be proprietary and confidential to Ingersoll – Rand and should not be reproduced without the prior written permission of Ingersoll – Rand. Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll – Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request. This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorised Ingersoll – Rand service department. The design specification of this machine has been certified as complying with E.C. directives. Any modification to any part is absolutely prohibited and would result in the CE certification and marking being rendered invalid. All components, accessories, pipes and connectors added to the compressed air system should be: . of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll – Rand. . clearly rated for a pressure at least equal to the machine maximum allowable working pressure. . compatible with the compressor lubricant/coolant. . accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll–Rand Service departments. The use of repair parts other than those included within the Ingersoll – Rand approved parts list may create hazardous conditions over which Ingersoll – Rand has no control. Therefore Ingersoll – Rand cannot be held responsible for equipment in which non – approved repair parts are installed. Ingersoll – Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The intended uses of this machine are outlined below and examples of unapproved usage are also given, however Ingersoll – Rand cannot anticipate every application or work situation that may arise. IF IN DOUBT CONSULT SUPERVISION. This machine has been designed and supplied for use only in the following specified conditions and applications: . Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles . Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual. The use of the machine in any of the situation types listed in table 1: – a) Is not approved by Ingersoll –Rand, b) May impair the safety of users and other persons, and c) May prejudice any claims made against Ingersoll –Rand.
M90 M110 M132 M160
TABLE 1 Use of the machine to produce compressed air for: a) direct human consumption b) indirect human consumption, without suitable filtration and purity checks. Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual. Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours. Use of the machine fitted with non Ingersoll–Rand approved components. Use of the machine with safety or control components missing or disabled.
The company accepts no responsibility for errors in translation of this manual from the original English version. SSR ULTRACOOLANT is a Ingersoll–Rand Company USA.
registered
trademark
of
INTELLISYS is a registered trademark of Ingersoll–Rand Company USA. © COPYRIGHT 2002
INGERSOLL –RAND COMPANY
ISO SYMBOLS
3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory
Information / Instructions
Warning
WARNING: Electrical shock risk.
WARNING – Pressurised vessel.
WARNING – Hot surface.
WARNING – Pressure control.
WARNING – Corrosion risk.
WARNING – Air/gas flow or Air discharge.
X,X
BAR
WARNING – Pressurised component or system.
WARNING – Hot and harmful exhaust gas.
WARNING – Maintain correct tyre pressure. (Refer to the GENERAL INFORMATION section of this manual).
0C
WARNING – Flammable liquid.
WARNING – Before connecting the tow bar or commencing to tow consult the operation and maintenance manual.
WARNING – For operating temperature below 0C, consult the operation and maintenance manual. M90 M110 M132 M160
4
ISO SYMBOLS
WARNING – Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved.
WARNING – Consult the operation and maintenance manual before commencing any maintenance.
Do not breathe the compressed air from this machine.
Do not remove the Operating and Maintenance manual and manual holder from this machine.
Do not stack.
Do not operate the machine without the guard being fitted.
Do not stand on any service valve or other parts of the pressure system.
Do not operate with the doors or enclosure open.
Do not use fork lift truck from this side.
Do not exceed the trailer speed limit.
No naked lights.
Do not open the service valve before the airhose is attached.
Use fork lift truck from this side only.
Emergency stop.
Tie down point
XX km/h
M90 M110 M132 M160
ISO SYMBOLS
Lifting point.
On (power).
5
Off (power).
a Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken.
When parking use prop stand, handrake and wheel chocks.
Contains asbestos.
SET
SEQUENCER STATUS
LOAD
SEQUENCER (AUTOMATIC CONTROL)
COMPRESSOR
OFF LOAD (UNLOADED)
RESET
COMPRESSOR STATUS
MODULATE
MALFUNCTION
POWER
SOILED FILTER
POWER INLET
ELECTRIC MOTOR
HOURS
M90 M110 M132 M160
6
ISO SYMBOLS
COOLANT SEPARATOR
PRESSURE
AIR DISCHARGE
PRESSURISED TANK
ON / OFF CYCLE
COOLANT FILTER
AIR FILTER
ON / OFF PUSH BUTTON
COOLANT PRESSURE
AIR PRESSURE
STAR DELTA IEC 617 –7
AUTOMATIC RESTART
HEAT EXCHANGER
MAINTENANCE
MAINTENANCE PROHIBITED
COOLANT DRAIN
CONDENSATE DRAIN
PRESSURE CONTROL
MANUAL (SELECT)
TEMPERATURE
HIGH TEMPERATURE
M90 M110 M132 M160
ISO SYMBOLS
BELT TENSION
FILTER
MOTOR LUBRICATION
FRAGILE
KEEP DRY
THIS WAY UP
USE NO HOOKS
NO SIDE CLAMPS
ROTATION
POWER INLET (AC)
WATER IN
WATER OUT
7
M90 M110 M132 M160
8
SAFETY
WARNINGS Warnings call attention to instructions which must be followed precisely to avoid injury or death. CAUTIONS Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings. NOTES Notes are used for supplementary information.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally. Avoid bodily contact with compressed air.
General Information
The safety valve located in the separator tank must be checked periodically for correct operation.
Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
Materials
Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure.
The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: . preservative grease . rust preventative . compressor coolant AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES For further information, consult Material Data Sheets ACGP 011/96 (Ultracoolant) and ACGP 029/90 (food grade coolant).
Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
Should compressor lubricant come into contact with the eyes, then irrigate with water for at least 5 minutes.
Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes.
Should compressor lubricant come into contact with the skin, then wash off immediately.
The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be affected by either synthetic lubricants, or the additives used in mineral oils. Metal bowls should be used on a pressurised system.
Consult a physician if large amounts of compressor lubricant are ingested. Consult a physician if compressor lubricant is inhaled.
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
Never give fluids or induce vomiting if the patient is unconscious or having convulsions.
Compressed air
Transport
Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.
When loading or transporting machines ensure that the specified lifting and tie down points are used.
All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure.
Electrical
If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidently be pressurised / over pressurised by another. Compressed air must not be used for a direct feed to any form of breathing apparatus or mask. The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible. If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided. When using compressed air always use appropriate personal protective equipment.
M90 M110 M132 M160
Keep all parts of the body and any hand – held tools or other conductive objects, away from exposed live parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the compressor electrical system. Close and lock all access doors when the compressor is left unattended. Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers suitable for class BC or class ABC fires. Attempt repairs only in clean, dry, well lighted and ventilated areas. Connect the compressor only to electrical systems that are compatible with its electrical characteristics and that are within it’s rated capacity.
SAFETY
9
Condensate disposal Condensate cannot be discharged into fresh/surface water drains. In some regions compressor condensate containing Ultracoolant can be fed directly into a drainage system that has downstream sewerage treatment. As waste water regulations vary by country and region it is the responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll – Rand and its associated distributors are happy to advise and assist in these matters. Coolant disposal Steps to be taken in the case of spillage: Soak up with a suitable absorbent material, then sweep into a plastic bag for disposal. Burn in an approved incinerator, or according to local area or country regulations. For further information, consult Material Data Sheets ACGP 011/96 (Ultracoolant) and ACGP 029/90 (food grade coolant).
M90 M110 M132 M160
10
GENERAL INFORMATION
LUBRICATION SYSTEM KEY A. LUBRICANT
5. ORIFICE & SCREEN
B. LUBRICANT / AIR
6. COOLANT FILTER
ENERGISED
7. COOLER
DE – ENERGISED
8. THERMOSTATIC VALVE
1. CHECK VALVE
9. SOLENOID VALVE (1SV)
2. DISCHARGE PIPE
10.INLET VALVE POSITIONING CYLINDER
3. SEPARATOR TANK
11.COOLANT STOP VALVE (5SV)
4. DRAIN VALVE
M90 M110 M132 M160
GENERAL INFORMATION
11
AIRFLOW SYSTEM KEY A. LUBRICANT
6. MODULATION SOLENOID VALVE (2SV)(OPTIONAL)
B. LUBRICANT / AIR
7. SOLENOID VALVE (4SV)
C. AIR
8. PRESSURE TRANSDUCER (1PS)
ENERGISED
9. CONDENSATE DRAIN
DE – ENERGISED
10.MOISTURE SEPARATOR (OPTIONAL)
1. FILTER
11.AFTERCOOLER
2. COMPRESSOR
12.MODULATOR (OPTIONAL)
3. CHECK VALVE
13.MINIMUM PRESSURE VALVE
4. TEMPERATURE SENSOR
14.BLOWDOWN VALVE (3SV, 8SV)
5. SEPARATOR TANK
M90 M110 M132 M160
12
GENERAL INFORMATION
WATERCOOLING SYSTEM KEY
The standard compressor is designed to operate in an ambient range of 1,7C to 46C. The standard maximum temperature of 46C is applicable up to an elevation of 1000m (3280ft) above sea level. Above this altitude significant reductions in ambient temperature are required if a standard motor is to be used.
A WATER IN B WATER OUT C. LUBRICANT OUT D. LUBRICANT IN E. LUBRICANT COOLER F. AFTERCOOLER G. AIR OUT H. AIR IN J. WATER
In water cooled compressors, the cooling water flows first to the aftercooler and then to the lubricant cooler. This series flow is designed to keep the total water requirement to a minimum (refer to T5328 – 1). By taking the cooling water to the aftercooler first, lower temperature air is discharged to the compressed air system.
GENERAL OPERATION The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package.
M90 M110 M132 M160
Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors. The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes to the aftercooler and out of the compressor through the moisture separator (optional). Air is pulled into the machine by the cooling fan and is pushed through the combined cooler / aftercooler. By cooling the discharge air and passing it through the separator, much of the water vapour which is naturally present in the air, can be removed. The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurised and forced to the compressor bearings. The compressor load control system is automatic ’On – Off line’. The compressor will operate to maintain a set discharge line pressure and is provided with an auto restart system for use in plants where the air demand varies widely.
13
GENERAL INFORMATION Panel instrumentation is provided to indicate the compressor operating conditions and general status.
Safety of operation is provided for as the compressor will shut down if excessive temperatures, electrical overload conditions, or system over pressure should occur.
(OPTIONAL) Modulation hardware extends the control types to Modulation (capacity control) and Automatic Control System when the compressor switches between ’On – Off line’ and modulation as demand varies.
M90AC
M110AC
M90WC
M110WC
PRESSURE
7,5 bar (L)
CAPACITY
16,7 15,3 14,00 20,0 19,2 17,5 16,7 15,3 14,00 20,0 19,2 17,5 m3 /min m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. 590 ft3 /min.
8,5 bar (M)
540 ft3 /min.
10,0 bar (H)
494 ft3 /min.
7,5 bar (L)
706 ft3 /min.
8,5 bar (M)
678 ft3 /min.
10,0 bar (H)
618 ft3 /min.
7,5 bar (L)
590 ft3 /min.
8,5 bar (M)
540 ft3 /min.
10,0 bar (H)
494 ft3 /min.
7,5 bar (L)
706 ft3 /min.
8,5 bar (M)
678 ft3 /min.
FULL LOAD CURRENT (MAXIMUM) 220V
361 A
431 A
344 A
414 A
FULL LOAD CURRENT (MAXIMUM) 380V
209 A
250 A
199 A
240 A
FULL LOAD CURRENT (MAXIMUM) 415V
201 A
240 A
192 A
231 A
STARTING CURRENT (MAXIMUM) 220V
847 A
977 A
728 A
858 A
STARTING CURRENT (MAXIMUM) 380V
511 A
578 A
442 A
509 A
STARTING CURRENT (MAXIMUM) 415V
547 A
624 A
484 A
561 A
*NOISE LEVEL CAGI PNEUROP 1m
74 ± 3
74 ± 3
74 ± 3
74 ± 3
10,0 bar (H)
618 ft3 /min.
* Equivalent continuous sound pressure level (workstation) (rated load) WEIGHT O.D.P.
2430 kg
2580 kg
2430 kg
2580 kg
WEIGHT T.E.F.C.
2700 kg
2850 kg
2700 kg
2850 kg
M90 M110 M132 M160
14
GENERAL INFORMATION M132AC
M160AC
CAPACITY
23,5 22,3 21,0 28,0 26,0 25,0 23,5 22,3 21,0 28,0 26,0 25,0 m3 /min m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. m3 /min. 742 ft3 /min.
7,5 bar (L)
989 ft3 /min.
8,5 bar (M)
918 ft3 /min.
10,0 bar (H)
883 ft3 /min.
7,5 bar (L)
830 ft3 /min.
8,5 bar (M)
788 ft3 /min.
10,0 bar (H)
742 ft3 /min.
7,5 bar (L)
7,5 bar (L)
788 ft3 /min.
10,0 bar (H)
M160WC
PRESSURE
830 ft3 /min.
8,5 bar (M)
M132WC
989 ft3 /min.
8,5 bar (M)
918 ft3 /min.
FULL LOAD CURRENT (MAXIMUM) 220V
545 A
626 A
481 A
606 A
FULL LOAD CURRENT (MAXIMUM) 380V
297 A
354 A
286 A
344 A
FULL LOAD CURRENT (MAXIMUM) 415V
289 A
340 A
281 A
330 A
STARTING CURRENT (MAXIMUM) 220V
1373 A
1457 A
1210 A
1325 A
STARTING CURRENT (MAXIMUM) 380V
746 A
781 A
719 A
713 A
STARTING CURRENT (MAXIMUM) 415V
806 A
835 A
785 A
767 A
*NOISE LEVEL CAGI PNEUROP 1m
75 ± 3
75 ± 3
75 ± 3
75 ± 3
* Equivalent continuous sound pressure level (workstation) (rated load) WEIGHT O.D.P.
2840 kg
2970 kg
2590 kg
2600 kg
WEIGHT T.E.F.C.
3075 kg
3075 kg
3190 kg
3000 kg
M90 M110 M132 M160
10,0 bar (H)
883 ft3 /min.
GENERAL INFORMATION
15
93167641
M90 M110 M132 M160
16
GENERAL INFORMATION
KEY CF1 – CF5 Control fuses CFO
Common fault output
CON Intellisys controller 3DP
Pressure switch (Fouled coolant filter)
E
Main earth
ELK
Earth link
ES
Emergency stop
FF
Fan fuses
FM
Fan motor
FOL
Fan motor overload relay
1HAT Temperature switch (Discharge) ISO
Isolator (customer supplied)
K1 – K4 Relay
The INTELLISYS controller enables the operator to customise the following parameters via the front panel: OFFLINE PRESSURE (Pressure bands 1 and 2) The discharge pressure at which the compressor unloads. ONLINE PRESSURE (Pressure bands 1 and 2) The pressure at which the compressor loads. PRESSURE BANDS Two pressure bands are selectable via the Intellisys controller. The pressure band may be changed during normal operation of the compressor by pressing the up arrow key () for pressure band 1 and the down arrow key () for pressure band 2. Pressures within each band cannot be changed whilst the compressor is in operation.
KM1
Main contactor
KM2
Delta contactor
STAR –DELTA
KM3
Star contactor
KM4
Fan contactor
Star – delta adjustment enables the operator to adjust the time which the motor remains in ’star’ during starting.
L1 – L3 Mains terminals MM
Main motor
MOL Main motor overload relay
AUTO RESTART If the compressor runs unloaded for a pre – determined time, it will shut down automatically to conserve power. This delay time is adjustable from 10 – 20 minutes.
PT
Pressure transducer
RSP
Remote stop
DELAY LOAD TIMER
RST
Remote start
1SV
Solenoid valve (Load)
2SV
Solenoid valve (Modulate)(Optional)
The compressor will load as soon as the discharge pressure falls below online pressure. By varying the delay load time, it is possible to smooth out pressure ripples in the system and avoid excessive on/off line cycling.
3SV
Solenoid valve (Blowdown)
4SV
Solenoid valve (Line/sump)
5SV
Solenoid valve (Coolant stop)
8SV
Solenoid valve (Cold start)
T1
Transformer (20VA)
T2
Transformer (130VA)
1TAS Temperature sensor (Discharge pipe) TR
Thermistor relay
4TS
Temperature switch (Cold start)
1VAC Vacuum switch (Fouled air filter) The compressor is controlled and protected by an INTELLlSYS microprocessor controller. The transformer provides the INTELLISYS unit with an 8 – 0 – 8 Vac power supply. By switching the 48Vac voltage, the microprocessor controls and sequences the motor contactors and the load solenoid. It continually monitors the status of the compressor, which is shown on a single line backlit Liquid Crystal Display (L.C.D.). Various machine functions can be displayed via the front panel buttons. If a fault occurs, the controller takes immediate action and indicates the cause of the fault. The emergency stop will stop the compressor independently of the INTELLISYS unit.
M90 M110 M132 M160
OPTIONS The controller can give remote start/stop control. It will also interface with the optional INGERSOLL – RAND sequencer. A power out restart option is also available, which will enable the compressor to automatically restart following an interruption of the power supply. CONTROL MODE The compressor runs in ON Line – OFF Line as standard. Modulation and A.C.S. modes are an option. Modulation will reduce the delivery capacity to a minimum of 60% of the capacity as stated on the data plate allowing a continuous delivery of air when required. A.C.S. mode automatically switches between modulation and on/off line to optimise performance and reduce running costs.
INSTALLATION / HANDLING
17
M90/110AC M90/160WC KEY A 2” BSPT
Air discharge (WC)
H
Cooling air exhaust
B 1 / 2” BSPT
Condensate drain (WC)
I
Control panel
C 11 / 4” BSPT Water in/out (WC) D 2” BSPT
Air discharge (AC)
E 1 / 4” BSPT
CONDENSATE DRAIN (AC)
F
Cooling air intake
J 100mm dia. Access panel to coolant drain
NOTE All dimensions are in millimetres unless otherwise stated.
G 100mm dia. Electrical cable entry
M90 M110 M132 M160
18
INSTALLATION / HANDLING
M132/160AC KEY A 2” BSPT B C
1 / ” BSPT 4
Air discharge
F
Condensate drain
G 100mm dia. Access panel to coolant drain
Cooling air intake
D 100mm dia. Electrical cable entry E
Control panel
Cooling air exhaust
M90 M110 M132 M160
NOTE All dimensions are in millimetres unless otherwise stated.
INSTALLATION / HANDLING UNPACKING / SHIPPING STRAP Remove the yellow shipping strap (identified by two red identification tags) as follows; 1. remove the polythene cover and front access panel from the machine, 2. remove the screw from the top of the starter cabinet, 3. remove the screw from the separator cover, 4. discard the strap and tags, 5. replace the screw in the separator cover and tighten to a torque of 96 ft.lbs (4,04Nm), 6. replace the access panel.
Model Range
19
Minimum cooling water requirement at ambient temperatures, in litres per minute (UK gallons per minute) 50F / 10C
70F / 21C
90F / 32C
M90
34(7.5)
45(10)
77(17)
M110
41(9)
59(13)
95(21)
M132
64(14)
82(18)
123(27)
M160
73(16)
95(21)
150(40)
Water temperature and pressure gauges should be installed in the water piping for use in any fault finding of the water system. Water pressure should ideally be between 3 and 5 bar. Water cleanliness is also extremely important. Cleaning of coolers as a result of fouling is a customer responsibility. Therefore, it is highly recommended that proper water quality must meet the requirements listed in WATER QUALITY RECOMMENDATIONS later in this section. Venting the water system
UNPACKING
At the initial installation or for start – up after draining the water system proceed to vent the system as follows
The compressor will normally be delivered with a polythene cover. If a knife has to be used to remove this cover ensure that the exterior paintwork of the compressor is not damaged.
1 Locate the water system vent cocks on top of the aftercooler and lubricant cooler. 2 Open the water valve(s) allowing water to flow to the package.
Incorporated within the base of the compressor are slots to enable a fork lift truck (2 ton minimum) to move the machine. Alternatively a special lifting frame can be supplied to enable a crane or hoist to move the compressor.
3 Open the vent cocks and allow all air to escape from the system. When water is observed at the vent cocks, close them The system is now vented. Draining the water system
WATER COOLED UNITS
Should it become necessary to completely drain the water system, proceed as follows.
Cooling Water Piping
1 Disconnect the inlet and discharge water lines from the connections located at the rear of the unit.
Water piping to and from the compressor package must be 1 1/4”diameter or larger. Isolation valves with side drains should be installed on both the inlet and outlet lines. Also a strainer of 2mm – mesh size should be installed on the inlet line. Strainers are available from Ingersoll – Rand. Ingersoll – Rand CPN 54690052.
2 Locate the aftercooler and lubricant cooler. Remove the drain plugs located at the bottom of the coolers. Allow the system to completely drain.
It is recommended that a normally closed solenoid valve be fitted to the water outlet side of the compressor package. This is to be wired into the compressor control circuit. This option detail is available from Ingersoll – Rand. Carefully inspect your water system before installing the compressor package. Ensure that the piping is free of scale and deposits that may restrict water flow to the compressor package. Proper operation of your compressor requires that the water flow listed below be provided at a maximum supply temperature of 32C
Water quality recommendations Water quality is often overlooked when the cooling system of a water – cooled air compressor is examined. Water quality determines how effective the heat transfer rate, as well as the flow rate will remain during the operation life of the unit. It should be noted that the quality of water used in any cooling system does not remain constant during the operation of the system. Evaporation, corrosion, chemical and temperature changes, aeration, scale and biological formations effect the water makeup. Most problems in a cooling system show up first in a reduction in the heat transfer rate, then in a reduced flow rate and finally with damage to the system.
M90 M110 M132 M160
20
INSTALLATION / HANDLING
Scale: Scale formation inhibits effective heat transfer, yet it does help prevent corrosion. Therefore, a thin uniform coating of calcium carbonate is desired on the inner surface. Perhaps the largest contributor to scale formation is the precipitation of calcium carbonate out of the water. This is dependent on temperature and pH. The higher the pH value, the greater the chance of scale formation. Scale can be controlled with water treatment. Corrosion: In contrast to scale formation is the problem of corrosion. Chlorides cause problems because of their size and conductivity. Low pH levels promote corrosion, as well as high levels of dissolved oxygen. Fouling: Biological and organic substances (slime) can also cause problems, but in elevated temperature environments such as cooling processes they are not a major concern. If they create problems with clogging, commercial shock treatment are available. To ensure good operation life and performance of the compressor cooling system, the recommended acceptable ranges for different water constituents are included below: Cooling Water Analyses Chart
Substances
Test interval
Acceptable concentration
Corrosivity (Hardness, pH, Total Dissolved Solids, Temperature at inlet Alkalinity)
Monthly — if stable for 3 to 4 months, analyse quarterly.
Langelier Index 0 to 1
Iron
Monthly
<2 ppm
Sulphate
Monthly
<50 ppm
Chloride
Monthly
<50 ppm
Nitrate
Monthly
<2 ppm
Silica
Monthly
< 100 ppm
Desolated Oxygen
Daily — if stable,analyse weekly
0 ppm (as low as possible)
Oil & Grease
Monthly
<5 ppm
Ammonia
Monthly
<1 ppm
SEA WATER COOLED UNITS It is important to ensure that the recommended flow rate cannot be exceeded. This will normally mean that an orifice plate must be fitted in the pipework at least 1m before the cooler, with the orifice size calculated to ensure that the maximum sea water flow rate cannot be exceeded. If these precautions are not taken, it is possible that the sea water flow rate through the cooler may be several times the recommended maximum, which will lead to rapid failure.
Sea Water Pressure in Bars
Orifice diameter in mm to give a maximum sea water flow of 120l/min
3 bar
13
4 bar
12
5 bar
12
6 bar
11
7 bar
11
8 bar
10
9 bar
10
10 bar
10
Water cleanliness is also extremely important. Strainers are available from Ingersoll – Rand. Cleaning of coolers as a result of fouling is a customer responsibility. Isolation valves with side drains should be installed on both the inlet and outlet lines. It is recommended that a normally closed solenoid valve be fitted to the water outlet side of the compressor package. No oil cooler manufacturer can guarantee that its products will have an indefinite life and for this reason, we suggest that the cooling system is designed to minimise any damage caused by a leaking oil cooler. This can be achieved as follows ; 1. The oil pressure should be higher than the sea water pressure, so that in the event of a leak occurring, the oil will not be contaminated . 2. When the hydraulic system is not being used, the coolers should be isolated from sea water pressure.
The Ingersoll – Rand Hydro – check cooling water analysis kit CPN89223481 provides a sample bottle and pre – addressed return tube to our laboratory, where a full report on water quality will be issued.
M90 M110 M132 M160
3. The sea water outlet pipe from the cooler should have a free run to waste.
INSTALLATION / HANDLING
21
T5326 Revision 02 06/03/01 LOCATION IN THE PLANT The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is as clean as possible is recommended.
It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected and installed they can reduce any liquid carryover to zero.
Sufficient space all round and above the compressor must be allowed, to enable the effective removal of the cooling air which, in turn, will reduce the risk of re – circulating the cooling air back through the compressor.
It is good practice to locate an isolation valve close to the compressor and to install line filters [4].
A minimum of 1 metre all round the compressor is recommended. If headroom is restricted, then the exhaust should be ducted or deflected away from the machine.
ELECTRICAL DATA
Hard surfaces may reflect noise with an apparent increase in the decibel level. When sound transmission is important, a sheet of rubber or cork can be installed beneath the machine to reduce noise.
Feeder cables should be sized by the customer/electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the compressor.
CAUTION:
It is recommended that provision be made for lifting heavy components during major overhaul.
An independent electrical isolator should be installed adjacent to the compressor.
Feeder cable connections to studs L1 – L2 – L3 on isolator should be tight and clean.
CAUTION Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.
CAUTION The use of plastic bowls on line filters and other plastic air line components without metal guards can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. From a safety standpoint, metal bowls should be used on any pressurised system.
The applied voltage must be compatible with the motor and compressor data plate ratings. The control circuit transformer has different voltage tappings. Ensure that these are set for the specific applied voltage prior to starting.
CAUTION Never test the insulation resistance of any part of the machines electrical circuits, including the motor without completely disconnecting the intellisys controller.
NOTE: Main and fan motor insulation must be tested by a competent electrician prior to initial start – up or following an extended shutdown period in cold damp conditions. DISCHARGE PIPING Discharge piping should be at least as large as the discharge connection of the compressor. All piping and fittings should be suitably rated for the discharge pressure.
NOTE Fuses F1 and F2 are supplied loose in the starter cabinet. Do not install until all electrical testing has been completed.
M90 M110 M132 M160
22
OPERATING INSTRUCTIONS
PRIOR TO STARTING
KEY
1. Check coolant level. Add if necessary. 1: PACKAGE DISCHARGE PRESSURE L.E.D. 2. Make sure main discharge valve is open. 3. Turn on electrical isolator. The power L.E.D. will illuminate and the display will indicate Ready to start’. ‘
This will illuminate when the display indicates the package discharge pressure. 2: AIREND DISCHARGE TEMPERATURE L.E.D. This will illuminate when the display indicates the airend discharge temperature.
WARNING Make sure that all protective covers are in place.
3: SUMP PRESSURE L.E.D. This will illuminate when the display indicates the sump pressure.
STARTING 1. Press Start’ [24]. The compressor will start and then load automatically. ‘
4: SEPARATOR PRESSURE DROP L.E.D. This will illuminate when the display indicates the separator pressure drop.
NORMAL STOPPING 1. Press Unloaded Stop’[25]. The compressor will unload then stop. ‘
2. Turn off electrical isolator. EMERGENCY STOP 1. Push Emergency Stop Button’ [26]. The compressor will stop immediately. ‘
2. Turn off electrical isolator.
CAUTION After shutdown never allow unit to stand idle with pressure in receiver/separator system. M90 M110 M132 M160
5: TOTAL HOURS L.E.D. This will illuminate when the display indicates the total compressor running hours. 6: LOADED HOURS L.E.D. This will illuminate when the display indicates the total loaded compressor hours. 7: LOAD/UNLOAD L.E.D. This will illuminate when the compressor is running onload . 8: MODULATION L.E.D. This will illuminate when the compressor is running in modulation mode. (Optional)
OPERATING INSTRUCTIONS 9: UNLOAD L.E.D. This will illuminate when the compressor is running in unload mode.
23
23:LOAD/UNLOAD BUTTON These are used to manually switch the compressor between a loaded control mode (e.g. on/off line ) and unloaded running.
10:ALARM L.E.D. See L.E.D. [7].
This will flash when a warning condition exists. The warning detected will be displayed and the compressor will continue to run. The warning can be reset by depressing set [22].
24:START BUTTON
It will illuminate when an alarm condition has occurred. The compressor will shutdown immediately. The alarm can be reset by depressing set [22] twice within 3 seconds.
This button when depressed will cause the compressor to start and load automatically, provided that the controller detects a demand for air. When pressed in the display mode, it will cause exit to checking machine for 2 seconds, then ready to start.
OTHER L.E.D.s
25:UNLOADED STOP
These will illuminate during the set point routine to indicate which function is being adjusted. 11:L.E.D. – Set off line pressure.
This button when depressed while the compressor is running, will unload the compressor (if not already unloaded) for 10 seconds and then stop. This is the normal method for stopping the compressor. If the compressor is already stopped, it will execute an L.E.D. check (all the L.E.D.s should illuminate) and display the controller software revision.
12:L.E.D. – Set on line pressure.
26:EMERGENCY STOP
13:L.E.D. – Select control mode.
This button when depressed will stop the compressor immediately and display an emergency stop alarm message.
14:L.E.D. – Set star delta time.
27:POWER L.E.D. This will illuminate when the 8V controller supply is available.
15:L.E.D. – Set auto restart time. 16:L.E.D. – Select options. 17:L.E.D. – Not used.
28:AUTOMATIC RESTART L.E.D. This will illuminate when the machine has shutdown due to low air demand. The compressor will restart and load automatically as soon as the demand for air resumes.
18:L.E.D. – Not used. DISPLAY MESSAGES
INSTRUMENT PANEL FUNCTION 19:LIQUID CRYSTAL DISPLAY This indicates the status of the compressor, set up parameters and warning/alarm messages. When the compressor is running, the display will normally show the package discharge pressure.
When the compressor is running normally, the display will indicate the package discharge pressure and illuminate the corresponding L.E.D. [1]. An arrow will also appear in the far right of the display indicating pressure band selection. Pressing display select [20] will change the display value and the corresponding L.E.D. will illuminate. The controller monitors all aspects of the compressor whilst running and will display warnings or in severe conditions execute an emergency stop and display alarm conditions.
20:DISPLAY SELECT BUTTON Press to index through compressor operating conditions. The corresponding L.E.D. will illuminate adjacent to display. This is used to select alternative status displays (after approximately 5 minutes, the display defaults to the package discharge pressure). Depressing this button in the set point routine will cause exit to checking machine for 2 seconds, then ready to start.
MACHINE CONTROL MODES CAPACITY CONTROL The compressor is fitted with ON LINE – OFF LINE control as standard. Modulation can be fitted as an option. If modulation is fitted it is activated by selection at the control panel. ON LINE – OFF LINE CONTROL
21:ARROW KEYS These are used to index through warning and alarm messages. In the set point routine, these buttons are used to increment/decrement set point values and enable/disable some operation conditions. The arrow keys are also used to select pressure bands 1 ( ) or 2 () during normal operation of the compressor.
For applications that require a widely varying air demand, this mode of control will deliver air at full capacity or zero capacity with low receiver pressure. This mode of operation is controlled by the pressure transducer (1PS) responding to changes in plant air pressure. This sensor energises the load solenoid valve (1SV) which in turn operates the venting valve (blowdown) and the closing of the atmospheric vent opening in the air inlet valve.
22:SET BUTTON Depressing this button when the compressor is stopped will enable entry into theset point routine . When in the set point routine , depressing this button will cause the controller to move on to the next set point setting, saving the new value if one has been entered. A warning reset is obtained by depressing this button (whilst the machine is running). An alarm reset is obtained by depressing this button twice within 3 seconds (the alarm condition will remain if the indicated fault has not been rectified).
The compressor then delivers full capacity air to the plant system. If the air pressure in this system rises to the upper set point of the pressure setting, the load solenoid valve is de – energised allowing the inlet valve to close. At the same time, the venting valve opens allowing the receiver pressure to drop. The pressure setting has a range of 0,83 bar between its upper and lower set points.The upper set point is set at 0,2 bar above the compessor rated discharge pressure. M90 M110 M132 M160
24
OPERATING INSTRUCTIONS
UPPER RANGE MODULATION CONTROL (OPTIONAL)
MOTOR OVERLOAD
For plants having a relatively high and constant air demand, Upper Range Modulation is the recommended mode of control.
The motor overload contacts are open. The motor overload must be reset before the controller can be reset.
Upper range modulation retains the features of On line – Off line control but provides the throttling of the inlet air flow as the line pressure rises to the upper set point of the off –l ine pressure setting.
REVERSE ROTATION
By bleeding off a small amount from the regulator valve, which energises the Modulate Solenoid Valve, a reduction in the air signal to the pneunatic cylinder on the inlet valve allows the cylinder to ‘trim’ the inlet valve position as dictated by changing line pressure. Modulation begins when the compressor reaches about 94% of the rated line pressure and is factory set to modulate down to aproximately 70% of rated capacity.
No sump pressure is detected after the first 2 seconds of running. Isolate the machine and reverse the mains supply connections before resuming. OVER PRESSURE The line pressure is 1 bar (15 psi) greater than the rated discharge pressure. TEMPERATURE SENSOR 1
If the air demand decreases to a level below the 70% modulated output, the line pressure will increase slightly to the upper limit of the pressure setting, when the compressor then changes to the Off line control position and operates with the receiver vented. CONTROLLER WARNING MESSAGES In the event of a warning, the controller will display a message and the alarm L.E.D. [10] will flash. The warning message will alternate with the normal display every 4 seconds, the compressor will continue to run but the fault should be rectified as soon as possible. The arrow keys [21] should be used to index the display for any additional warning messages. A warning message may be reset by depressing set [22] once.
The airend temperature sensor/ connecting cable has failed. Refer to diagram T5106 PRESSURE SENSOR Indicates pressure transducer failure / connecting cable fault. FAILED CALIBRATION During calibration routine, a 10% of scale error has been detected. Ensure that the separator is completely blowndown and repeat calibration.
NOTE: The warning will recur if the fault has not been rectified. The following warning messages may be displayed:
[CONTROL POWER OR]
COOLANT FILTER
REMOTE START FAILURE
The pressure differential across the coolant filter exceeds 1 bar.
The 48Vac supply is not present at the controller, or: –
Momentary remote start has not disengaged before star – delta transition. This alarm is active only if the remote start/stop is enabled.
AIR FILTER The air filter is dirty or blocked and should be replaced.
REMOTE STOP FAILURE The momentary remote stop switch has not disengaged when the start signal is received. This alarm is active only if the remote start/stop is enabled.
SEPARATOR ELEMENT The separator element is dirty or blocked and should be replaced.
EMERGENCY STOP AIREND TEMPERATURE
The emergency stop button is engaged.
The airend temperature reaches 97% of the high airend temperature set point (i.e. 106 C).
CONTROLLER ALARMS
In the event of an alarm, the controller will execute an emergency stop, the alarm L.E.D. [10] will illuminate and an alarm message will be displayed. The arrow keys [21] should be used to index the display for any additional alarm messages. An alarm is reset by depressing set [22] twice within a 3 second period after the fault has been rectified. The compressor will restart only when all alarm conditions have been rectified. The following alarm messages may be displayed (For fault correction see the Fault Finding section): STARTER FAULT The contactor sequence during start or stop is incorrect. AIREND TEMPERATURE The airend discharge temperature is above the high temperature set point.
M90 M110 M132 M160
LOW SUMP PRESSURE The sump pressure drops below 1bar during normal operation. MAINTENANCE PROMPTS The service warning and flashing LED will appear after the first 150 hours and every 2000 hours thereafter, cycling every 2 seconds with the current display message. The customer can only reset the warning for 24 hours by pressing the “set” button. Ingersoll – Rand service engineers will master reset the warning after completing the service work. The service warning will return each subsequent 2000 hours. The machine will be master reset after service work conducted prior to the 2000 hour interval to prevent false indication.
AIRCARE WARRANTY
25
Superior Service Solutions for Air Systems
AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased system reliability. The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficien cy, and reduced production losses through fewer unexpected maintenance requirements and downtime. An optional feature, Intelliguard is used to reduce downtime by remote monitoring.
Air Care Options Unit Status
Coverage
Service Level
Sign up for AirCare within the warranty period
Five Year Drivetrain or Package coverage
Inspection and diagnostic service only or Preventative maintenance and diagnostic service
To enroll in AirCare or Intelliguard, contact your local Ingersoll – Rand representative today.
M90 M110 M132 M160
26
MAINTENANCE
PERIOD
MAINTENANCE
PERIOD
MAINTENANCE
Daily
Check the coolant level and replenish if necessary.
When the separator element indicator light flashes
Check the pressure differential.
2000 hours M90/110/132/150 TEFC
Lubricate the main motor drive end bearing. Quantity of grease required: 30g
4000 hours
Lubricate the main motor non –d rive end bearing. Quantity of grease required: 20g
First 150 hours
Change the coolant filter.
8000 hours / 2 years
Each week
Check that the safety valve easing gear moves freely.
Replace the Ultracoolant at whichever interval occurs first.
1 month
Check the operation of the high temperature protection switch(es) (109C standard or 100C for TUV applications)
4 years
1 month
Check the cooler(s) for build up of foreign matter. Clean if necessary by blowing out with air or by pressure washing.
() To determine the correct letter designation (B,L) consult the CPN field on the main motor data plate.
1 monthly intervals.
On water cooled and sea water cooled models check the water input line strainer for build up of foreign matter, clean if required
Each 3 months
Check all hoses for signs of deterioration, cracks, hardening etc.
Each 2000 hours
Change the coolant filter.
6 months
Check the calibration of the pressure transducer.
1 year
Change the air filter element. Replace the element sooner if the indicator light flashes.
* Change the separator element if the pressure drop is zero or exceeds 1 bar (15 p.s.i.g.)
8000 hours / 1 year
Check the scavenge screen for blockage, clean if required.
1 year
Remove the safety valve from compressor, inspect and re – calibrate.
4000 hours M90 ODP
Lubricate the main motor drive end bearing. Quantity of grease required: B: 20g () L: 40g ()
Lubricate the main motor drive end bearing. Quantity of grease required: B: 40g () L: 40g () Lubricate the main motor non –d rive end bearing. Quantity of grease required: B: 20g () L: 40g ()
B: 4000 hours () L: 2000 hours () M132/160 ODP
Replace all hoses.
NOTE
Note: On some sea water cooled models the oil cooler and after cooler are fitted with sacrificial zinc anodes (pencils) that are located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500 hours. NOTE: 1 If sacrificial zinc anode is 50% corroded it should be replaced. 2 Coastal/harbour waters can contain corrosive chemicals from pollution and may reduce anode/cooler life. 3 Effects of corrosion or erosion are specifically excluded from warranty considerations.
the
Lubricate the main motor non –d rive end bearing. Quantity of grease required: B: 16g () L: 40g () 4000 hours M110 ODP
Also replace the separator element and coolant filter.
Lubricate the main motor drive end bearing. Quantity of grease required: B: 40g () L: 50g () Lubricate the main motor non –d rive end bearing. Quantity of grease required: B: 20g () L: 50g ()
WARNING Do not under any circumstances open any drain valve or remove components from the compressor without first ensuring that the compressor is FULLY SHUT – DOWN, power isolated and all air pressure relieved from the system.
* Caution: The separator tank lid and element are heavy and should only be removed using suitable lifting equipment. Never try to remove by hand. Wear protective gloves due to potential sharp edges/burrs. COOLANT LEVEL CHECKING PROCEDURE The coolant level should be checked daily. A coolant level sight glass is located on the side of the separator tank and while the machine is running on load, coolant should always be visible in the sight glass. The normal position is half way. ADDING COOLANT Run the compressor for a minimum of 40 seconds before stopping, then add coolant until the level is up to the mid – point of the sight glass. COOLANT FILTER CHANGE PROCEDURE .
Loosen filter element with the correct tool.
.
Remove the element from the housing.
.
Place the old element in a sealed bag and dispose of in a safe way.
.
Clean the mating face of the housing.
. Remove the new Ingersoll – Rand replacement element from its protective package. .
Apply a small amount of lubricant to the element seal.
. Screw the new element down until the seal makes contact with the housing, then hand tighten a further half turn. .
M90 M110 M132 M160
Start the compressor and check for leaks.
MAINTENANCE SSR ULTRACOOLANT – CHANGE PROCEDURE (Capacity [75] litres) It is better to drain the coolant immediately after the compressor has been operating as the liquid will drain more easily and any contaminant will still be in suspension. .
Position a suitable container under the drain plug.
.
Remove the plug and completely drain the coolant.
.
Replace the coolant filter.
.
Replace the separator element.
.
Replace the plug and refill the compressor.
27
CAUTION Do not use any form of sealant on either the separator tank or the separator tank cover faces.
.
Re – assemble the components in reverse order.
.
Start the compressor and check for leaks.
WARNING Do not remove the staple from the anti –static gasket on the separator element since it serves to ground any possible static build –up.
AIREND BEARINGS .
CAUTION – DO NOT MIX OILS WITH SSR ULTRACOOLANT.
Airend bearings are lubricated by the compressor coolant and require no maintenance. MOTOR BEARINGS
.
Start the compressor and check for leaks.
.
Check the coolant level, refilling if necessary.
. Dispose of waste coolant in accordance with local and governmental regulations.
Clean the area around the inlet and outlet plugs before removing the plugs. Add the specified quantity of recommended grease using a hand lever gun. Replace the inlet plug, run the machine for 10 minutes and then replace the outlet plug. MOTOR BEARING LUBRICANT SPECIFICATION Use ESSO UNIREX N3 grease or equivalent .
NOTE Shorter coolant drain intervals may be necessary if the compressor is operated in adverse conditions.
AIR FILTER CHANGE PROCEDURE .
Unscrew the retaining nut and withdraw the old elements.
.
Fit the new element ensuring that the retaining nut is secured.
CAUTION:
Do not over pack the motor bearings with grease as this may lead to motor failure.
CAUTION:
Ensure dirt and/or other contaminants are not introduced into the bearing during the greasing process.
SEPARATOR ELEMENT CHECKING PROCEDURE
H.A.T. SWITCH CHECKING PROCEDURE
With the compressor running on load, depress the line/sump selector. It will be necessary to change the element if the differential pressure equals zero or exceeds 15 psig (1 bar).
It is recommended that the temperature switches (1TAS and 2TAS) are checked regularly as follows:
SEPARATOR ELEMENT CHANGE PROCEDURE
AIr cooled machines Stop the cooling fan by opening the fan motor circuit breaker.
.Disconnect the scavenge tube from the airend and loosen the fitting that secures the scavenge tube to the separator tank cover and then remove the scavenge tube.
Water cooled machines Shut off the cooling water.
.
The machine should trip at 109C standard, 100C TUV application.
Disconnect all piping from the separator tank cover.
. Remove the setscrews securing the cover to the tank and remove the complete cover assembly. CAUTION:
* Heavy cover – use lifting equipment
Under no circumstances should these discharge temperatures be exceeded. If the machine fails to trip A FAULT EXISTS. Investigate immediately.
. Withdraw the used element, place it in a sealed bag and dispose of it safely. * Wear safety gloves against sharp edges
The temperature at which the machine stops should be recorded for comparison with future results.
.
Clean the gasket surface on both the tank and the cover.
HIGH BEARING TEMPERATURE SWITCH (5TAS)
.
Install the replacement element.
Should the airend bearing temperature reach 109C standard or 100C TUV application, the machine will stop. M90 M110 M132 M160
28
MAINTENANCE
COLD START / RAPID WARM –UP SWITCH (4TS) The purpose of this switch is to reduce the unloaded sump pressure to save energy (refer section on dual blowdown system) and to automatically load the compressor when there is a demand for air – providing the service switch is set to the load position. The switch is set to open at 49C.
T5359 Revision 01 09/94
KEY
NOTE – It is important that the correct size spanner is used and on no account must a stillson type wrench be used on any part of this componemt. Tighten the cap to a torque of 150Nm (110 lb.ft.)
1. Housing 2. Cap 3. Disc
The scratches should be over the area covered by and extending beyond the outer seat face.
4. Filter & screen 5. Retaining cap OPERATION On the underside of the disc [3] is a machined circular groove, whilst the opposite side is plain with a single scratch toward the outer edge. The unit is best suited to clean operating conditions. If the operating conditions are dirty, unscrew the cap and turn over the disc so that the plain side with a bleed scratch is toward the seating faces. In extremely dirty conditions, it may be necessary to deepen the bleed scratch or to make additional scratches up to a maximum of 3. Replace the cap using a suitable high temperature anti – seize grease on the thread.
M90 M110 M132 M160
TO SERVICE Unscrew the cap using a spanner. If the disc and body are only slightly worn, they can be refurbished by lapping individually on a flat surface plate. If the wear is too great to be rectified, the whole assembly must be replaced. The filter can be removed and cleaned. To re – assemble, replace the filter and retaining cap .A fine smear of molybdenum disulphide grease should be applied to the threads.
MAINTENANCE
29
KEY
Slide the travel stop bracket D as far as possible in the direction of the arrow.
1: UL88 modulator (Optional)
Rotate the air inlet valve shaft counter clockwise until the butterfly valve E is in the closed position.
2: Cylinder 3: Coolant pressure 4: Vent
Ensuring that the butterfly valve E is closed, position the linkage arm F against the travel stop bracket D.
5: Inlet air flow 6: Line pressure (modulate) (Optional) 7: Vent (Optional) 8: Inlet valve
Tighten the screw B to secure the linkage arm F to the shaft. INLET VALVE POSITIONER LINKAGE ADJUSTMENT Refer to diagram T5360
9: Open 10:Closed
Ensure that the modulator lever G is against the stop H. (If fitted) Ensure that the linkage arm F is against the travel stop bracket D.
NOTE: – Parts of this section refer to the modulation system, which may not be fitted if you have a standard machine.
Adjust the length of the inlet valve positioner linkage P until the screw A threads easily into the linkage arm F. Tighten screw A.
INLET CONTROL VALVE ADJUSTMENT Refer to diagram T5360 Remove screw A securing the cylinder to the linkage arm F.
UNLOADED RUNNING RECEIVER PRESSURE ADJUSTMENT Refer to diagram T5360 An indicator line should be scribed horizontally on the butterfly valve spindle to record the position of the valve.
Loosen screw B securing the linkage arm F to the shaft. Loosen screws C securing the travel stop bracket D to the mounting bracket.
Using the stop bracket D and screws C push the linkage arm F clockwise until the scribed line is at approximately 10and then tighten the screws C. M90 M110 M132 M160
30
MAINTENANCE
Start the compressor and allow it to reach its normal working temperature. (Refer to STARTING THE MACHINE in the OPERATING INSTRUCTIONS section).
Allow the machine to reach its normal operating temperature, then load the machine. This allows the load cylinder to be actuated, opening the inlet control valve E and loading the compressor.
Using the service load/unload button located on the control panel, unload the compressor.
Open the isolation valve and set the discharge pressure to 0,3 bar below the rated operating pressure which is stated on the compressor data plate.
Close the isolation valve. Using the stop bracket D and screws C with the display reading sump pressure, adjust the inlet valve stop until the sump pressure reads 1,7 to 2,0 bar on the display. (Clockwise increases the pressure). The compressor is now operating correctly unloaded and can be returned to load mode after opening the isolation valve.
Confirm that the air inlet valve is fully open and then stop the compressor normally. Press the SET button [4] and select SELECT CONTROL MODE. Press the arrow keys [3] until the MODULATION option is displayed. Restart the compressor. Air flow should then be detected coming from the orifice (vent 7) located in the bottom of the modulator body K. Turn the modulator adjusting screw M until the lever G begins to move off the stop H.
MODULATOR ADJUSTMENT (OPTIONAL) Refer to diagram T5360
NOTE: Confirm at this stage that the line pressure has remained steady and that the air inlet valve is still fully open.
Remove the nut J from the modulator K. Loosen the locknut L and adjust screw M a few turns Start the compressor and run it with modulation mode off.
M90 M110 M132 M160
Whilst holding adjusting screw M firm, tighten the locknut L. Replace nut J. Raise the line pressure by means of the isolation valve to just below the off –l ine pressure setting. Set the adjustment lockbolt N so that it just makes contacts with lever G. Tighten the locknut on the bolt.
MAINTENANCE
Refer to diagram T5307 The INTELLISYS controller enables the user to adjust the operating parameters of the compressor to suit the application. To enter set point adjustment depress set [22] when the display shows ready to start . The arrow keys [21] are used to increment or decrement values or parameters. Depressing set [22] stores the new value and moves on to the next value.
↑
102 PSI
§
31
P2 = P1 – 0,3bar (5psi) max. 4,4bar (65psi) min.
INCREMENT VALUE 0,1bar (1psi)
READY TO START OFFLINE PRESSURE (Pressure band 1) OFFLINE PRESSURE (Pressure band 2)
112 PSI
↑
ML 7,7bar (112psi) max. (maks.) MM 8,7bar (126psi) max. (maks.) MH 10,0bar (145psi) max. (maks.) MU 13,0bar (189psi) max. (maks.) ALL 5,1 bar (75psi) min. INCREMENT VALUE 0,1 bar (1psi)
112 PSI
↑
ML 7,7bar (112psi) max. (maks.) MM 8,7bar (126psi) max. (maks.) MH 10,0bar (145psi) max. (maks.) MU 13,0bar (189psi) max. (maks.) ALL 5,1 bar (75psi) min. INCREMENT VALUE 0,1 bar (1psi)
ONLINE PRESSURE (Pressure band 1) M90 M110 M132 M160
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MAINTENANCE SEQUENCER ENABLE/DISABLE (Only functions if an Ingersoll – Rand sequencer is connected) ONLINE PRESSURE (Pressure band 2)
SEQUENCER OFF ON/OFF
102 PSI
§
↑
P2 = P1 – 0,3bar (5psi) max. 4,4bar (65psi) min.
INCREMENT VALUE 0,1bar (1psi) REMOTE START/STOP ENABLE/DISABLE (Compressor will only start/stop via remote signalling) REM START OFF CONTROL MODE
REMOTE START ON/OFF
ON/OFF LINE ON/OFF LINE/ (MODULATION/ AUTOMATIC CONTROL SYSTEM (OPTIONAL)) DELAY LOAD TIME Delay between the online signal and compressor load. DELAY LOAD TIMER
STAR –DELTA TIME
0 – 60 SECONDS
5 SEC 4 – 15 SECONDS
OFF –LINE PRESSURE 112 PSI
↑
AUTO RESTART TIME 10 MIN OFF/10 – 20 MINUTES
CHECKING MACHINE
READY TO START
§
KEY P1 = OFFLINE PRESSURE P2 = ONLINE PRESSURE
M90 M110 M132 M160
FAULT FINDING
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FAULT
CAUSE
REMEDY
’Power on’. L.E.D. does not illuminate.
CONTROL VOLTAGE NOT AVAILABLE
Check the control fuses.
Controller indicates trip condition.
CONTROL CIRCUIT INTERRUPTED BY A SAFETY DEVICE
Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault persists investigate further.
Compressor trips indicating a high compressor temperature.
INSUFFICIENT COOLANT CIRCULATION
Check the coolant level.
Check the transformer secondary windings for the control voltage.
Check the temperature sensor Change coolant filters Check the operation of thermostatic valve and oil stop valve
Compressor trips and indicates motor overload.
POOR ELECTRICAL CONNECTION
H.A.T. thermistors fail-safe. The unit will trip due to open or short circuit.
INSUFFICIENT COOLING TAKING PLACE
Check that the cooling air flow is not obstructed at: . The inlet to the package . The cooler matrix . The exhaust vents
EXCESSIVELY HIGH AMBIENT TEMPERATURE (i.e. greater than 46oC (115oF).
Improve the ventilation to the compressor room.
INSUFFICIENT COOLING TAKING PLACE
If machine is water cooled or seawater cooled, check that the cooling water is flowing. Check that there is no air in the water cooling system. Check that the strainer is not blocked.
EXCESSIVE CURRENT HAS CAUSED THE THERMAL OVERLOAD (MOL) TO TRIP
Check the actual operating pressure and lower the setting if it is too high. Isolate the electrical supply and check that the airend and motor rotate freely. Check the separator element for excessive pressure drop. Check supply voltage
ISOLATION VALVE CLOSED.
Open the valve and restart.
BLOWDOWN SYSTEM INEFFECTIVE.
Check the operation of the load solenoid.
Compressor will not build up rated pressure.
DEMAND TOO HIGH
Check for leaks, open service valves or exceptionally high demand.
OFFLINE PRESSURE SET TOO LOW
Check the offline pressure setting.
Compressor will not load.
INLET VALVE NOT OPENING
Check that the valve is free to open.
Compressor fails to deliver rated capacity.
–
Compressor shutdown. Display shows OVERPRESSURE.
Check the operation of the unloader valve – strip and clean if necessary.
Check the operation of the load solenoid valve 1SV. Check the operation of the inlet valve. Check the operation of the load solenoid valve 1SV. Check the offline/online pressure setting. Check the inlet filter for contamination. The L.E.D. should indicate if it is blocked.
Excessive coolant consumption.
BLOCKED SCAVENGE LINE
Clear the blockage.
RUPTURED OR FOULED SEPARATOR ELEMENT
Change the element.
Rapid cycling or receiver will not blow –down to unloaded running pressure.
RAPID LOAD/UNLOAD CYCLING
Duty cycle too rapid – Increase system capacity.
MINIMUM PRESSURE VALVE (MPV) STUCK OPEN
Strip the MPV, examine and repair if necessary.
Safety valve blows when compressor goes on load.
MPV STUCK CLOSED
Strip MPV, examine and repair if necessary.
SAFETY VALVE FAULTY
Check the setting of the safety valve and the rated pressure.
BLOCKED SEPARATOR ELEMENT
Check pressure differential and replace
M90 M110 M132 M160
